Case Study - PT Newmont

5/26/2018 Case Study - PT Newmont

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ETAP RealETAP Real--Time ProjectsTime ProjectsPT NewmontPT Newmont


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ConfidentialETAP Rep Symposium December 2005

System DescriptionSystem Description -- LocationLocation

Copper-Gold Mine

Sumbawa-Indonesia

Project held by PT Newmont Nussa Tenggara

(PTNNT)


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System DescriptionSystem Description -- ProcessProcess

Open Pit Mine

Use Electrical Shovels

and Mechanical Drive Trucks to Transport the Ore

Handles Around 600,000 t/d of Ore and Waste

0.49% Copper and 0.39g/t Gold


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System DescriptionSystem Description -- ProcessProcess

From Primary Crusher Ore Transported on a

6.8 km Overland Conveyor

In Concentrator Sag and

Ball Mills Produce32% Copper and

19.9 g/t of Gold

Ore is Pipelined to Benette (port) for Sea

Transport


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System DescriptionSystem Description -- ElectricalElectrical

Power Plant

4 Steam Turbine Generators 34MW each

9 Diesel Generators 5 MW each

Power Plant Located Next to Benette Transmission

2 - 15kM Lines to Concentrator and MineSubstations


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Concentrator Loads

4 Ball Mills (10K HP) and 2 Sag Mills (13.4MW)

Other Process Loads Including Pumps, Fans,etc.

Mine Loads

Shovels, Primary Crusher Motors, Township,etc.


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Why ETAP RealWhy ETAP Real--TimeTime

for PT Newmont ?for PT Newmont ?


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Process Time LossesProcess Time Losses

Repeated Productions Losses

Faults caused by animals in the transmissionsystem

Load variation caused instability in thegenerators when operating at maximum load

Too Much Load Variation

Could not shed shovels, port, or other variableloads because never knew how much wasshed


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Process Time LossesProcess Time Losses

Only Constant Loads

Sag Mills, Ball Mills, Overland Conv. Process time lost if any of those loads tripped

$300K+ lost every trip on those loads

High Generation Cost

Had to run many diesels generators during

normal operation Keep spinning reserve high and improve

reliability


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ETAP RealETAP Real--TimeTime -- SolutionSolution

ETAP ILS Provides PTNNT

Monitoring of each sheaddable feeder and

load

Right combination of loads to trip

Unlimited Load Priority Tables i.e. Winter

process changes and therefore load priority

changes


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Load Shedding against:

One steam generator trip

Multiple generators trip

Boiler trips


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Old SCADA LimitationsOld SCADA Limitations

Costly to expand

Low performance

Limited trending and no reporting features

Primitive calculations techniques i.e. wrongfrequency display for 2 min when one Gen goesoffline

No remote control for line breakers and processloads


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Real-Time Monitoring provides PTNNT:

Complete monitoring of the system

Control of their transmission and distributionbreakers

Trending, archiving, reporting of mainparameters:

Frequency, generation, powertransmission, power generation, energyconsumption


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How was it accomplished?How was it accomplished?


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ETAP RealETAP Real--TimeTime -- ProjectProject

Divided on Three Phases

Phase 1

Modeling and system studies

Communication network design and

implementation Phase 2

Data collection system and ETAP Real-Time setup

Phase 3

Load shedding setup and installation


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Project StepsProject StepsPhase 1Phase 1

ETAP Model Verification

Newmont already have an ETAP model

System data sent to OTI office for modelverification

Metering Evaluation

General Electric SR relays in place

Studies data collection speed requirements

Load variation


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System Studies to determine:

Steady and transient stability limits

Max. allowable load shedding time

Min. load to shed for certain events Triggers


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Communication Network Design

Best method of networking existing metersDetermined meters to replace

Report and drawings submitted to Newmont

Communication Network Implementation

Done in house by PT Newmont Engineers

Replacement of 12 relays to URs for maximumdata collection

Phase 1 completion, about 3 Months


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Data Collection System Setup

OPC Server installation and setup

Setup done at OTI offices

Installation and tuning done onsite 1 weektrip

ETAP Real-Time Server Installation

Done in conjunction with OPC Server setup


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Primary and Auxiliary Console Setup

Remote Control

Playback

Real-Time MonitoringArchive Server for Reporting

Phase 2 Completion 2 Months


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PLC Programming

Trigger Handling

Priority Table Handling

Performed in OTI Tested Onsite by OTI and Newmont Engineers

Timing Fine Tuned Onsite


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ETAP ILS Server installed

Separate from Real-Time Server for reliabilitypurposes

Trigger Communication

Wired triggers to PLCs

Routed some triggers using IP tunneling


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Complete test of communication

Monitoring

ILS calculations with real system data

Triggers tested Final SAT

Phase 3 completion, about 3 months

Case Study - PT Newmont

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